Vacuum Sander

ABSTRACT

A vacuum sander includes a head assembly. A handle attachment is rotatable coupled to a drive to allow selective rotation of the handle attachment relative to the drive and a debris shroud about a first axis. The drive is rotatable relative to the debris shroud to allow selective rotation of the drive and the handle attachment relative to the debris shroud about a second axis different from the first axis. The drive is rotatably coupled to a forked handle attachment between two prongs thereof. The drive is configured to couple to a sanding implement and to selectively drive rotation of the sanding implement about an axis.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. Provisional Ser. No.63/216,997, filed Jun. 30, 2021, the entirety of which is incorporatedby reference herein.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a vacuum sander.

BACKGROUND OF THE DISCLOSURE

A motorized vacuum sander may be used to sand drywall and reduce cleanup time by collecting dust and debris while sanding drywall compound,for example. A dust collection system may be coupled to the motorizedsander whereby a vacuum draws the sanded drywall dust into a dustcollecting vessel as the drywall compound is removed.

SUMMARY

In one aspect, a vacuum sander generally comprises an elongate handle; aforked handle attachment coupled to the elongate handle, wherein theforked handle attachment includes two prongs; and a drive coupled to theforked handle between the two prongs thereof, wherein the drive isconfigured to couple to a sanding implement and to selectively drivemovement of the sanding implement.

In another aspect, a head assembly for a vacuum sander generallycomprises a forked handle attachment configured to couple to an elongatehandle, wherein the forked handle attachment includes two prongs; adrive rotatably coupled to the forked handle attachment between the twoprongs thereof, wherein the drive is configured to couple to a sandingimplement and to selectively drive rotation of the sanding implementabout an axis; and a debris shroud coupled to the drive and configuredto enclose the sanding implement when coupled to the drive.

In yet another aspect, a head assembly of a vacuum sander generallycomprises a handle attachment configured to couple to an elongatehandle; a drive configured to couple to a sanding implement and toselectively drive rotation of the sanding implement about an axis; and adebris shroud configured to enclose the sanding implement when coupledto the drive. The handle attachment is rotatable coupled to the drive toallow selective rotation of the handle attachment relative to the driveand the debris shroud about a first axis. At least a portion of thedrive is rotatable relative to the debris shroud to allow selectiverotation of said at least a portion of the drive and the handleattachment relative to the debris shroud about a second axis differentfrom the first axis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of one embodiment of a vacuum sander constructedaccording to the teachings of the present disclosure.

FIG. 2 is an enlarged perspective of a sanding head of the vacuumsander;

FIG. 3 is an exploded view of FIG. 2 .

FIG. 4 is an exploded view of a drive of the sanding head.

FIG. 5 is a right perspective of a housing body of a belt-drivetransmission of the drive.

FIG. 6 is a left perspective of a housing body of a belt-drivetransmission of the drive.

FIG. 7 is an exploded view of a gearbox transmission of the drive.

FIG. 8 is a bottom perspective of the gearbox transmission, with a wormand an output shaft of the belt-drive transmission exploded therefrom.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring to FIG. 1 , one embodiment of a vacuum sander is generallyindicated at reference numeral 10. The illustrated vacuum sander 10 issuitable for sanding drywall, as is generally known in the art. Ingeneral, the vacuum sander 10 includes a sanding head, generallyindicated at 12; an elongate handle or pole 14 coupled to the head andextending distally therefrom; and a control 16 coupled to the handle 14.Referring to FIG. 2 , as explained in more detail below, the sandinghead 12 includes a drive, generally indicated at 17 (e.g., anelectrically-powered drive), configured to drive rotation of a sandingdisc (not shown) coupled to the head assembly; a debris shroud 18coupled to the drive; and a handle attachment, generally indicated at19, coupling the handle to the drive. The illustrated debris shroud 18includes ribs on an upper surface thereof to provide rigidity to theshroud to maintain flatness.

Referring still to FIG. 1 , the handle 14 is hollow and defines a vacuumpassage 20 extending along its length between its proximal and distalends in fluid communication with the vacuum passage of the head 12. Theexterior of the illustrated handle 14 has a polygonal (e.g., octagonal)cross-sectional shape, although it may have other shapes. The handle 14may be adjustable in length (e.g., telescoping). The proximal end of thehandle 14 is operatively coupled to a vacuum source 21 configured topull a vacuum or create negative pressure within the handle and the head12. As an example, a flexible tube 22 fluidly connects the handle 14 tothe vacuum source 20. A canister or container 24 is fluidly connected tothe vacuum source 21 to collect debris being drawn from the head 12 andthrough the handle 14.

As shown in FIG. 1 , the control 16 is coupled to the handle 14 betweenthe proximal and distal ends. The control 16 includes one or moreactuators (e.g., button, lever, or the like) in electrical communicationwith the drive 17 of the head assembly 12 and configured to actuateoperation of the head assembly (i.e., rotation of the sanding disc)and/or the vacuum source 21. Referring to FIG. 2 , the control 16 iselectrically connected to the drive 17 via an electrical wire 30 otherelectrical conductor extending along the handle 14. As shown in FIG. 1 ,the control 16 is electrically connectable to a power source via anelectrical cord 32 or other electrical conductor extending proximallyfrom the proximal end of the handle 14. The use of the actuator(s) ofthe control 16 selectively supplies power from the power source to thedrive 17. In another embodiment, the vacuum sander 10 may bebattery-operated and a battery (e.g., a rechargeable battery) may becoupled (e.g., mounted on) the sander.

Referring to FIGS. 2 and 3 , the handle attachment 19 is forked andincludes two prongs (e.g., upper and lower prongs 40 a, 40 b) convergingat a coupling 42 configured to be fastened (such as by screw, bolts, orother fasteners) to the distal end of the handle 14. Each of the prongs40 a, 40 b and the coupling 42 defines a portion of a vacuum passage ofthe head 12 in fluid communication with the vacuum passage 20 of thehandle 14. Each of the prongs 40 a, 40 b is rotatably coupled to thedrive 17 at a drive coupling 40 to allow selective rotation of theattachment 19 and the handle 14 about a first axis A1 (FIG. 2 ) relativeto the debris shroud (and the drive). The prongs 40 a, 40 b are alsofluidly connected to a portion of the vacuum passage of the head 12extending through the drive, as explained in more detail below. Thedrive 17 is received in the space between the prongs 40 a, 40 b toprovide clearance for the attachment 19 and the handle 14 to rotateabout the first axis A1. In one example, the attachment 19 is rotatableabout 180 degrees about the axis A1.

Referring to FIG. 4 , the drive 17 includes an electric motor 50electrically connected to the control 16; a belt-drive transmission,generally indicated at 52, operatively coupled to the electric motor;and a gearbox transmission, generally indicated at 54, operativelycoupled to the belt-drive transmission. Mechanical power is transmittedfrom the electric motor 50 to the sanding disc through the belt-driveand gearbox transmissions 52, 54, respectively. The electric motor 50includes an output shaft 60 that is rotatably driven about an outputaxis OA1. A fan 62 is coupled to the output shaft 60 to produce air flowthrough the belt-drive transmission 52 to cool the motor 50. In oneexample, the motor 50 is a universal motor, although it may be of othertypes. In another embodiment, the motor may be another type of motorother than electrical, such a pneumatic.

Referring to FIGS. 3 and 4 , the belt-drive transmission 52 includes abelt-drive housing 70, and a belt assembly 72 in the housing. Thebelt-drive housing 70 includes a housing body 74, a belt assembly cover76, and a divider 78 sandwiched between the housing body and the beltassembly cover. The output shaft 60 of the motor 50 extends into thebelt-drive housing 70 through the housing body 74. The fan 62 isreceived within a cavity 80 defined by the housing body 74 and a fanportion of the divider plate 78 overlies the fan to capture the fanwithin the cavity. A bearing 86 coupled to the output shaft 60 of themotor 50 is received in an opening 88 in the divider plate 78 to allowrotation of the output shaft.

The belt assembly 72 includes an input shaft 90 coaxially coupled to theoutput shaft 60 of the motor 50 for rotation about the axis OA1 of theoutput shaft; an input gear 92 coupled to the input shaft for rotationabout the axis OA1 of the output shaft; an output gear 96 coupled to theinput gear by a toothed belt 98 and configured to rotate about itscenter; and an output shaft 100 coaxially coupled to the output gear forrotating about its axis OA2. The input and output gears 92, 96 and thebelt 98 are received in the cover 76 and on the side of the dividerplate 78 opposite the housing body 74. The output shaft 100 of the beltassembly 72 extends through an opening 102 in the divider plate 78 andis coupled to a bearing 104 received in the opening. The diameter of thefirst gear 92 is less than the diameter of the second gear 96. Forexample, the gear ratio may be from about 3:1 to about 6:1, or othersuitable ratios.

Referring to FIG. 7 , the gearbox transmission 54 includes a gearboxhousing 110 defining a gear compartment into which the output shaft 100of the belt assembly 72 extends. As shown in FIG. 2 , the belt-drivehousing 70, and in particular the housing body 74, is rotatably coupledto the gearbox housing 110 such that the belt-drive transmission—alongwith the motor 50, the attachment 19, and the handle 14—is rotatablegenerally about an axis A2 that is coaxial with the output axis OA2 ofthe output shaft 100, although the axis of rotation A2 may not becoaxial with the output axis OA2 in other embodiments. The gearboxtransmission 54 further includes a worm 111 coupled to the output shaft100 of the belt assembly 72; a worm gear 112 engaging the worm; and anoutput shaft 114 coaxially coupled to the worm gear for rotation aboutits axis OA3. The output shaft 114 extends through an opening 118 in anupper surface of the debris shroud 18. The output shaft 114 isconfigured to couple to a sanding disc within the shroud 18. Bearings120 are disposed within the gearbox.

As can be understood from the above description, in operation the outputshaft 60 of the motor 50 is rotatably driven to impart coaxial rotationof the input shaft 90 and input gear 92 of the belt assembly 72.Rotation of the input gear 92 drives axial rotation of the output gear96 and output shaft 100 of the belt assembly 72 via the belt 98.Rotation of the output shaft 100 of the belt assembly 72 drives rotationof the worm 111, which in turn drives rotation of the worm gear 112 andthe output shaft of the gearbox transmission to rotate the sanding disc.

As mentioned above, the drive 17 defines the portion of the vacuumpassage that fluidly connects the debris shroud 18 to the handleattachment 19 and the handle 14. In this regard, the vacuum passage isdefined the coupling 40, the belt-drive housing body 74, and the gearboxhousing 110. The coupling 40 defines upper and lower downstream openings120 a, 120 b fluidly connecting the prongs 40 a, 40 b of the forkedattachment 19 and a coupling plenum 124 defined by the coupling. Thecoupling plenum 124 is fluidly connected to a housing plenum 126 definedby the housing body 74 and the divider plate 78. The divider plate 78separates the vacuum passage and the belt assembly cover 76. The housingbody 74 defines an opening 128 (e.g., an annulus) to fluidly connect thehousing plenum 126 to a gearbox plenum 130 in the gearbox housing 110. Aboss 140, which may include a bearing, for the output shaft 100 of thebelt-drive transmission 52 extends through the opening 128, whereby thevacuum passage extends around the boss. As shown in FIG. 8 , the gearboxplenum 130 extends from a lower surface of the gearbox housing 110 andis in fluid communication with one or more openings 134 in the uppersurface of the debris shroud 18.

As can be understood from the above description, in operation the vacuumpulls a vacuum or creates negative pressure within the vacuum passage todraw debris from the sanding disc, through the sanding head 17, theattachment 19, and the handle, into the container 24. The debris flowsthrough the openings 134 in the debris shroud 18 and into the gearboxplenum 130. From the gearbox housing 110, the debris flows through thehousing body 74 of the belt-drive transmission 52, into the plenum 124of the coupling 44. From the coupling plenum 124, the debris is drawninto the handle attachment 19, and then into the vacuum passage of thehandle 14 where it exits and enters the container 24.

Modifications and variations of the disclosed embodiments are possiblewithout departing from the scope of the invention defined in theappended claims.

When introducing elements of the present invention or the embodiment(s)thereof, the articles “a”, “an”, “the” and “said” are intended to meanthat there are one or more of the elements. The terms “comprising”,“including” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

As various changes could be made in the above constructions, products,and methods without departing from the scope of the invention, it isintended that all matter contained in the above description and shown inthe accompanying drawings shall be interpreted as illustrative and notin a limiting sense.

What is claimed is:
 1. A vacuum sander comprising: an elongate handle; aforked handle attachment coupled to the elongate handle, wherein theforked handle attachment includes two prongs; and a drive coupled to theforked handle between the two prongs thereof, wherein the drive isconfigured to couple to a sanding implement and to selectively drivemovement of the sanding implement.
 2. The vacuum sander set forth inclaim 1, wherein the drive is rotatably coupled to the two prongs of theforked handle attachment to allow for selective rotation of the forkedhandle attachment and the elongate handle relative to the drive about anaxis.
 3. The vacuum sander set forth in claim 2, wherein the drive isdisposed in a space between the two prongs to provide clearance for thedrive as the forked handle attachment rotates about the axis.
 4. Thevacuum sander set forth in claim 3, wherein together the handle, theforked handle attachment and the drive define a vacuum passage extendingtherethrough and configured to provide fluid communication between thesanding implement and the vacuum source.
 5. The vacuum sander set forthin claim 1, wherein the drive comprises an electric motor.
 6. The vacuumsander set forth in claim 1, wherein a proximal end of the handle isconfigured to be fluidly connected to a vacuum source.
 7. The vacuumsander set forth in claim 1, further comprising a control coupled to thehandle, the control including an actuator in electrical communicationwith the drive configured to actuate operation of the drive.
 8. Thevacuum sander set forth in claim 1, wherein the drive includes a motor,a gearbox transmission having an output shaft configured to couple tothe sanding implement for rotating the sanding implement about the axis,and a belt-drive transmission operatively connecting the motor to thegearbox transmission.
 9. The head assembly set forth in claim 8, whereinthe belt-drive transmission is rotatably coupled to the gearboxtransmission to allow selective rotation of the belt-drive transmission,the motor, and the forked handle attachment relative to the gearboxtransmission and the debris shroud.
 10. A head assembly for a vacuumsander comprising: a forked handle attachment configured to couple to anelongate handle, wherein the forked handle attachment includes twoprongs; a drive rotatably coupled to the forked handle attachmentbetween the two prongs thereof, wherein the drive is configured tocouple to a sanding implement and to selectively drive rotation of thesanding implement about an axis; and a debris shroud coupled to thedrive and configured to enclose the sanding implement when coupled tothe drive.
 11. The head assembly set forth in claim 10, wherein thedrive includes a motor, a gearbox transmission having an output shaftconfigured to couple to the sanding implement for rotating the sandingimplement about the axis, and a belt-drive transmission operativelyconnecting the motor to the gearbox transmission.
 12. The head assemblyset forth in claim 11, wherein the belt-drive transmission is rotatablycoupled to the gearbox transmission to allow selective rotation of thebelt-drive transmission, the motor, and the forked handle attachmentrelative to the gearbox transmission and the debris shroud.
 13. The headassembly set forth in claim 11, wherein the drive is rotatably coupledto the two prongs of the forked handle attachment to allow for selectiverotation of the forked handle attachment and the elongate handlerelative to the drive about an axis.
 14. The head assembly set forth inclaim 13, wherein the drive is disposed in a space between the twoprongs to provide clearance for the drive as the forked handleattachment rotates about the axis.
 15. The head assembly set forth inclaim 11, wherein together the forked handle attachment and the drivedefine a vacuum passage extending therethrough and configured to providefluid communication between the sanding implement and a vacuum source.16. A head assembly of a vacuum sander comprising: a handle attachmentconfigured to couple to an elongate handle; a drive configured to coupleto a sanding implement and to selectively drive rotation of the sandingimplement about an axis; and a debris shroud configured to enclose thesanding implement when coupled to the drive, wherein the handleattachment is rotatable coupled to the drive to allow selective rotationof the handle attachment relative to the drive and the debris shroudabout a first axis, wherein at least a portion of the drive is rotatablerelative to the debris shroud to allow selective rotation of said atleast a portion of the drive and the handle attachment relative to thedebris shroud about a second axis different from the first axis.
 17. Thehead assembly set forth in claim 16, wherein the handle attachment isrotatable about the first axis in a first plane, wherein together saidat least a portion of the drive and the handle attachment are rotatableabout the second axis in a second plane, wherein the first and secondplanes are transverse to one another.
 18. The head assembly set forth inclaim 16, wherein the drive includes a motor, a gearbox transmissionhaving an output shaft configured to couple to the sanding implement forrotating the sanding implement about the axis, and a belt-drivetransmission operatively connecting the motor to the gearboxtransmission.
 19. The head assembly set forth in claim 18, wherein thebelt-drive transmission is rotatably coupled to the gearbox transmissionto allow selective rotation of the belt-drive transmission, the motor,and the forked handle attachment relative to the gearbox transmissionand the debris shroud.
 20. The head assembly set forth in claim 17,wherein together the forked handle attachment and the drive define avacuum passage extending therethrough and configured to provide fluidcommunication between the sanding implement and a vacuum source.